Post Graduate Program in CAD

Course Syllabus
 Course one:
Ultimate
SOLIDWORKS
Course
1.Introduction
In this course, you will learn about the solid modelling and surface modelling tools of the CAD software - SOLIDWORKS.
SOLIDWORKS is a dynamic software used primarily in R&D sectors. SOLIDWORKS is widely used in the concept generation
stage of production. It gives designers real-time results in product modelling.

Students from mechanical engineering can enrol in this course. In this course, you will be learning the fundamentals of
concept generation.

At the end of this course, you will be fluent in both solid as well as surface modelling tools. After the completion of this
course, you will become eligible for the role of a CAD engineer using SOLIDWORKS. This course is specifically designed for
design engineers who are interested in the product concept generation phase. After the completion of this course, you will
understand the basics of SOLIDWORKS including - part modelling, assembly modellings, photo-realistic renderings.

2.Creating your own concept sketches

You will learn to create professional mood boards and initial ideation sketches in Adobe Photoshop. You will learn how to
import & blend images, add watermarks and color. You will also learn how to design an American Chopper and how to
render this design in Photoshop.
3.Introduction to
SOLIDWORKS &
Mastering
SOLIDWORKS
User Interface
You will be introduced to SOLIDWORKS and will learn how
to customize the shortcuts. You will learn solid modelling
techniques in SOLIDWORKS while modelling the
Transmission belt, Kickstand, and Fenders of an American
Chopper. You will also learn how to add appearance to the
parts of the bike.

4.Advanced Sketching &

Solid Modeling
In this module, you will learn how to create advanced sketches using curved driven patterns and patterns such as sketches,
projected, and composite curves. You will also learn how to create complex shapes while modelling the wheels, chassis, and
engine.

5.Assembly Techniques
You will learn the use of mates to provide relationships between parts in an assembly. You will also learn how and why advanced
mates such as angle mates are provided to limit the rotation of parts.
6.Rendering
In this module, you will learn how to add decals, lights,
and cameras as a preprocessing step before the final
rendering. You will be taken through the complete
rendering process with PhotoView 360 and
SOLIDWORKS Visualize using which you will be
creating high-quality images during the final rendering.

7.Surface Modelling
In this module, you will learn about the surface modelling feature in SOLIDWORKS. You will learn how to create a part
using a reference surface. You will be taught advanced surface modelling features while creating various parts of the Yacht
such as Hull, the Superstructure, and Seats. You will learn how to add decals and appearance for the parts and assembly.
 Projects Overview
1.Designing, Modelling, Assembly and
Photo-realisticRendering of an American Chopper
In this project, you will sketch and build a complete road-ready
Harley Davidson bike using SOLIDWORKS In this project you will learn
about how to create cut extrudes, revolve cuts, lofts, circular patterns
for modelling - Setting up of reference planes - curve generation -
projected curve creation understanding how to insert the parts in
assembly workspace - Creation of mates - Difference between float
and fix parts - Width mates application You will also learn how to create
photorealistic renderings with realtime appearances and views.
The following list is the key parts/models you will be dealing with
under solid modelling using SOLIDWORKS.

Transmission belt, front & rear fender modelling

Chain, side stand & pedals modelling
Front & rear wheel modelling
Engine modelling
Chassis for American Chopper designing
Front fork designing
Oil tank designing
Creating the assembly of American Chopper
Performing the rendering on assembly created by using Photoview 360 and SOLIDWORKS Visualise as the rendering tool

2.Modelling and Assembly of an American Predator Yacht

In this project, you will be able to sketch and build an entire American Predator Yacht using SOLIDWORKS. In this project you will
learn curve generation, surface creation from curves and sketches, different types of surfaces - boundary surfaces - lofted surfaces
- filled surfaces - ruled surfaces- reference planes - surface trims - surface knit - move/copy surfaces - mirror surfaces The following
are the key parts/models you will deal with in surface modelling using SOLIDWORKS.
Blueprint setup
Modelling of propellers, radars
Modelling of the hull, garage doors
Modelling of rear seats. middle seats, front seats.
Creation of the superstructure
Final assembly model of the Predator Yacht
Course Two:
SOLIDWORKS
Boeing 747
Design
1.Introduction to SOLIDWORKS
Surface Modelling Interface
Sketching tools
Surface modeling tools
Types of tools to create the surfaces
Blueprint setups

2.Curve Generation
Spline
Spline vectors
Equal curvature for splines
Constraining the splines
Projected curve creation
Composite curve generation

3.Surface creation from curves and sketches

Types of Surfaces
Boundary surfaces
Lofted Surfaces
Filled Surfaces
Ruled Surfaces
Reference Planes
Surface Trims
Surface Knit
Move/Copy Surfaces
Mirror Surfaces

4.Application of solid modelling

Revolve Boss
Extrude cut
Linear & circular patterns
Fillets
Chamfers
Split Bodies
Creation of wheels
5.Introduction to
Assembly Module
Inserting the parts
Mates in assembly
Sub assembly creations
Difference between Float and fix parts
Importing sub-assemblies to other assemblies
Application of Decals
Appearances adjustment

Project Overview
Project 1 - Modeling & Assembly
Modeling and Assembly of Boeing-747
Blueprint setup
Modelling of fuselage and nose
Modelling of windshields, passenger windows and window wipers
Modelling of wings and stabilizers
Creation of landing gears, wheels and wing flaps
Creation of nose gear and wheel sub-assembly.
Modelling Turbojet Engine
Final assembly model of Boeing-747
Course three:
Automotive
Sheetmetal
Design
using NX CAD
1.Introduction
The Automotive Sheet Metal Design using NX CAD course provides an outline of the current Body in White (BIW)
component design factors and detailed explanations about their significance to part function, cost, and reliability. In this
course, the modern design methodology is examined, covering Design for Manufacturing and Assembly and how
determining product end-use requirements is essential to creating successful contemporary products.

Upon completion of this course, you will have a comprehensive understanding of the physical and theoretical design
factors that must be considered during the creation of first-rate BIW components. You can start your career as a design
engineer in any sheet metal domain and with 2 to 3 years of experience, you can become a full-fledged BIW engineer.

2.Vehicle development cycle

YThis is an introductory session where students are introduced to the basics of automobiles along with different models
of car bodies. Students will also learn about the different stages of vehicle development that a car will go through before
reaching the customer. Students will also learn about the three years of development activity that precedes the
development of an automotive model.

3.Basics of Automotive Body in White

In this session, the student will be introduced to the basics of automotive BiW. The student will be introduced to the
basics of steel and its properties in detail because steel is an important component used in the construction of
automobiles. The steps that are followed in the selection of the material will be discussed as well. Students will be given
an introduction into cross-functional teams that exist in an organization, and the need to coordinate with them along
with examples of master sections and 3D components of the parts for easy and clear understanding.
 4.Design Methodology
of a Hood, Fender,
Roof, Back Doors
& Side Doors
In this module, we will focus our attention on the Hood,
Fender, Roof, Side doors and Back doors. The design
procedures for all the afore-mentioned parts can be
summarized as follows.
Design Requirements
Functional Requirements
Regulations
Gap and Flushness Requirements
Safety Requirements

5.Case study - Converting - RUECKWANDTUER

INNER PANEL
In this module, we will present a real-life scenario where the effect of converting an inner panel from aluminium cast to the steel
deep draw part is shown. Here is a quick summary of this case. The following design parameters were identified as critical and
hence were fully described:
Seal surface width was the same as the aluminium liftgate
Tailgate outer parting was maintained as the same
Liftgate thickness was modified
Gap and flushness were maintained
When you enroll in this course, you will be able to clearly understand these design parameters and the decisions that were
made. In this case study, the design guidelines were set through a series of CAE simulations.

6.Design of key mechanism - Lock and Striker

In this module, you will first learn the anatomy of a Locker and Striker mechanism. In order to be a successful product
development engineer, it is very important to understand in detail the development process and design requirements
for even the tiniest components. In this module, we will be analyzing the locker and striker mechanism in detail.
 7.Process &
challenges with
supplier
manufactured parts
In this module, we will look at two case studies.
Both of these studies focus on supplier manufacturing
practices. We will discuss the design challenges
faced by two Asian Automotive suppliers and then
go over the solution methodologies

Project Overview
Project 1 - Hood Design
In this particular project, you will be working on designing the inner panel of the hood, according to euro cap standards
and ensuring that the designed part can be manufactured.
You will provide all the necessary reinforcements at the necessary regions and join the outer and inner panel using the
proper joining methods.
You will also make sure that all the manufacturing requirements are being satisfied with the CAD parts that you design.

Project 2 - Fender Drip Area Design

In this particular project, you will be working on designing the drip area for the given fender, where you will make sure to
follow certain dimensions that are required to be followed for the drip area.
In addition to that, you will also provide the necessary bead and other emboss to strengthen the component.
You will need to ensure that the output part meets all the tolerances that need to be satisfied for the deep drawing
process.
Project 3 - Roof Design
In this particular project, you will develop the ditch area and roof reinforcements.
You will also be doing calculations to see if the roof passes the snow load criteria and heat distortion criteria.
The number of bow roof rails will also be calculated from the above calculation.

Project 4 - Tailgate Design

In this project, you will develop the inner panel of a tailgate by suggesting a tooling direction. While also ensuring that the
inner panel clears the draft analysis
You will also be doing calculations to see if the roof passes the snow load criteria and heat distortion criteria.
The number of bow roof rails will also be calculated from the above calculation.
Course Four:
Automotive
Seating Design
using CATIA V5
1.Introduction to Automotive
Seating
In this section, we will have a brief on Introduction of Automotive Structure, Seats & its Nomenclature.

2.Current Fashion/Trend
In this section, we will have a brief on types of Seats, how the seats are defined as per the number of rows in the Car and Number
of Movement in the seat.

3.Component of Seats
This section contains information about the parts/component used to design/develop a seat as per the requirement from the
customer. It will also have a basic mechanism used in a seat to provide the movements. It is defined in two segments:
Front Row Components
Rear Row Components

4.Component Details : Foam

In this section, we will brief about the components - Foam. Following points will be covered during the course with a hands-on
CATIA model.
How many types of Foam are available
Design Standard for Foam
Methods of foam development/Manufacture
Defects in Foam

5.Component Details : Structure

In this section, we will brief about the components – Structure. Following points will be covered during the course with a hands on
Catia model.
Types of Structure
Component of Structure
Design guideline
The material used in manufacturing
Methods used to develop structure
6.Component Details :
Headrest
In this section, you will learn the following
Types of Headrest used in automotive seats.
Components used in making headrest
Use of Headrest

7.Component
Details : Trims
In this section, you will learn the following.
Types of Trims used in Automotive
The terminology used in Trims
Defects during the development of trim
Methods to assemble trims

8.Component Details : Plastics

Following points will be covered during the section:
Types of Plastic ( Material/Usage differentiation)
Nomenclature of plastic parts in the seat
Efficient ways to use plastic in a seat
Defects occur on plastic components

9.Component Details : Armrest

In this section, you will learn the following.
Types of Armrest
Mechanism of Armrest
Components of an Armrest
Manufacturing Defects of Armrest

10.Component Details : Mechanism

In this course we will brief about details of all the mechanism used inAutomotive passenger seats including types of
Mechanism used and nomenclature:
Recliner – Work/Function and detail study
Track – Work/Function and detail study
Height Adjuster – Work/Function and detail study

11.Seat Testing
In this course will provide a glimpse of testing of seat at Car/Seat level which will include below:
Safety related Test
Regulatory related Test
 12.Comfort and
Innovation
In this course will provide a glimpse of testing of a
seat at Car/Seat level which will include below :
Comfort mechanism
New Innovation Idea
Comfort layouts of Seats

13.Seat Related Issues

This section of the course will not be only generalized to
seating but this method can be used all over the globe in
any domain to solve a problem:

8D
Fish Bone Diagram
5D
Man-Machine Diagram

14.DFMEA and PFMEA

This section of the course will not be only generalized to seating
but this method can be used all over the globe in any
design-related program :

What are DFMEA and PFMEA

The process to prepare DFMEA and PFMEA
Different Review points of DFMEA and PFMEA

15.GD&T
This section of the course will not be only generalize to seating but this methods can be used all over globe in any design
related program :

Introduction to GD&T
Usage of GD&T in seats
Different examples to define GD & T with exercise to do

16.Program Life Cycle

This section of the course will not be only generalized to seating but this method can be used all over the globe in any program :
Life Cycle of a program
Different stages a program goes
MileStones of Customers
 Projects Overview
Project 1

The Cad provided is a IGS file without any history. It is front row back foam. Use Under build / Over
build technology. Make use of the foam terminology. Make foam parametric and use standards
for making the parts.
The Complete design should be parametric.
Use Best Practices as Explained.
Use of best practice and maximum use part design.
The Cad provided is a IGS file without any history. It is front row cushion foam. Use Under build /
Over build technology. Make use of the foam terminology. Make foam parametric and use
standards for making the parts.
The Complete design should be parametric.
Use Best Practices as Explained.

Project 2
The Cad provided is a IGS file without any history. Remaster
the Solid using best practice as per below :
The Complete design should be parametric and by changing any
dimension the complete Part should get updated.
Use Best Practices as Explained
Use Part Design workBench.
Use the minimum number of commands for making the part.

The Cad provided is a IGS file without any history. Remaster the Solid using best
practiceas per below :
The Complete design should be parametric and by changing any dimension the
complete Part should get updated.
Use Best Practices as Explained
Use Part Design workBench.
Use the minimum number of commands for making the part.
8 D – Problem Solving
For a program launched in June 2020 we are facing a issue , the H Point of the Seat is not as per the OEM given value . The
issue is observed in 56 car Seat set out of total production of 3250 cars.
The issue is observed in Foam. The Foam Hardness is not as per Specs.
Use 5 M, Pugh, and other technical logical reasoning ways to solve the issue.

1 – A seat needs to be designed for which track peel out strength need to be calculated. The hand calculation need to be done
for which following details are provided :
H – Point : X – 1175.4 mm , Y – 337.5 mm , Z – 390 mm
Weight of the seat : - 18 Kg
CG – same as H – Point
Alpha Angle : 3 Degree
Beta Angle : 3.7 Degree
Mounting Point :
Point 1 :
X - 1093 mm
Y – 290 mm
Z – 298 mm
Point 2 :
X - 1169 mm
Y – 390 mm
Z – 307 mm

Calculate the strength of the Track (Peel Out Strength) required.

Course Five:
Automotive
Plastic Design
using CATIA V5
1.Design Overview In
Automotive Industry
You will learn about the following topics,
Product Life Cycle
Design Life Cycle

2.Plastics in Automotive Industry

Types of plastics (Thermoset Plastics, Thermoplastic)
Engineering plastic Materials
Manufacturing Process
Injection Molding

3.Introduction to CATIA
You will learn about the following,
Basic commands and operation.
Save, pan, rotate etc.

4.Sketcher workbench
You will learn about the following,
Commands
Rules to follow
Working in exercise

5.Part Design Workbench

You will learn about the following,
Commands
Rules to follow
Working in exercise

6.Advanced part design

You will learn about the following,
Boolean operations
Working on Boolean exercise
Working on After Tool Go modification on Automotive components. (OEM Working procedures)
7.Creation of PCB
Bracket using Boolean
operations
Create a PCB Bracket using Boolean operations

8.Surface design workbench

You will learn about the following,
Commands (Types of Sweep)
Working on exercise
Draft analysis
Working on surface exercise

9 Advanced Surface design work bench

You will learn about the following,
Commands
Creation of Closed body, Thickened body
Parting line, parting surface

10.Creation of Door Switch Bezel and add

thickness to it
You will learn about the following,
How to create tooling direction and do the draft analysis to ensure the part can be taken out of the tool?
Adding right thickness to the part and solve the issues
Create the parting line for the bezel

11.Creation of the positioning and fixation

features for Trim Bezel – Locator & a Fixation
In this section,
We will learn on what is a mounting feature
How to create a locator and dog house
Integrating the mounting features to the base part with Boolean operations

12.Creation of Clip locking mounting feature

& Snap for the Trim Bezelture
We will learn,
What is the clip mounting feature in plastic design
Design considerations for creating this feature
Tooling analysis for the clip feature
13.2D drawing creation
Drafting work bench.
Creation of detail drawing for the components
Views creations (basic view & section views)
Application of GD&T in drawings
Template settings

14.Tooling feasibility
In this section we will learn on what is a mounting feature
How to create a locator and dog house?
Integrating the mounting features to the base part with Boolean
operations

15.Molding exercise 1
Creation of simple mold for the rear quarter trim cup-holder
What is core and cavity
Stripper, ejection and system
Draft analysis
Designing a mold gives a good working understanding in the molding aspects of a component

16.Molding exercise 2
Instrument panel bezel with undercut
Creation of mold with side core, and lifter
Clear picture of undercut and other tooling complications
Draft analysis for complex part

17.Plastic defect
Plastic defects faced in automotive design
Real-time examples and solution for these designs

18.Creation of IP Console trim – Medium complex design

Component out of complex class-A surface
Solving class-A before starting design (OEM procedure)
Complex surfaces that cannot be thickened easily
Draft analysis to check the part for tooling.
OEM standard output presentation
19.Assembly Work Bench
Assemble automotive sub-assemblies including child part, screws
How to create assemblies in CATIA
Creating constraints
Assembly sectioning analysis
Proximity analysis and output preparation.
Compare analysis of 2 similar components OEM working procedure

20.Door Trim design with master section

Develop door trim from surfaces, and master section
Develop fixation and feature from door trim
Develop switch bezel from studying master section.
Gap and flush analysis
OEM standard output presentation

Projects Overview
Project 1 - Development of Car side door switch bezel
Creating the CAD model of switch bezel from the following inputs
Given Class A surface
Plastic component thickness
Draft angle requirements
Create the draft direction for manufacturing using the injection molding technique
Class B creation by maintaining a constant thickness
Closing surface creation based on proper draft angle and parting line for core and cavity design
Project 2 - Coin Holder
Creating a solid model of coin holder from given Class A inputs
Check for draft analysis and make modifications
Modify class A to meet the requirements. Prepare a report of changes made to Class A
Follow the procedure to create the solid model following plastic component design techniques
Check if the product can be manufactured by using draft analysis.

Project 3 - B pillar cover

Create a B pillar from the given class A with engineering features
Create a solid model from the given class A by following plastic design rules
Prepare dog houses and locators for matching the part with main B pillar
Create the location for proper fixing of part
Add rib feature to add strength to part
Do draft analysis with respect to main tooling direction and slider direction.

Project 4 - Heat Staking

Creating heat stakes for joining the plastic door applique to the metal substrate
Design the 4 way and 2-way locators for the plastic applique
Understand the heat staking process
As per the design rules design the heat stakes to join the door applique with the metal part.
Course six:
Automotive
Lighting Design
using CATIA V5
1.Basic of Lighting &
Software Overview
Some Old school phenomena of Physics-related to lighting
How basic physics use into real-time application
Basic name and application of Automobile lighting Ex –Headlight, tail light etc.
The function of light, example - turn indication, High beam, Low Beam
CATIA basic model, workbench, some basic command (in CATIA)
Some practice session on basics features, Like, boss, Locators (in CATIA)

2.Basic of Regulation & Start of Making Lamp

Information about regulations and its function
Start making Lamp (Class A analysis) (in CATIA)
B surface creation (all into separate parts in CATIA)
Feature implementation (in CATIA)
More deep information for Regulation and How to Check into 3D
Draft analysis, Basic check for Model(in CATIA)

3.Advance Level of Regulation with 3D Model &

Plastics Introduction
Basic Plastic, understanding while designing parts (in CATIA)
Making joining section (Glue, hot plate, Vibration etc)
Making all in single files (in CATIA)
Publish command in CATIA and join all parts together
Making mounting concept with 3,2,1 Principle surrounding check (in CATIA)
C regulation into 3D (in CATIA)
 Basic Tooling Check &
Drawing Making
Checking all data as per tooling requirement( only basic) in CATIA
Start making a 2D drawing from 3D ((in CATIA)
Tolerance, Dimension (in CATIA)
Complete revision (basic only)
Making small Lamp again as per regulation, plastic and Tooling requirement
Understanding Industry requirements, Optics, thermal, RFQ and other key
elements to getting into this domain

Projects Overview
Project 1 - 3D Drawing
Create complete 3D following a given section. Every area section should be the same, without changing given surfaces

Project 2 - Tail lamp design

Create a complete tail lamp using a hot plate welding section
Lens rib height - minimum 8-10 mm
Interference - 1.5 mm
The thickness of lens - 2.5 mm
Housing thickness - 2 mm
Reflector thickness - 2 mm
Boss - m4x10 screw
Positive mounting for the lamp - m5 screw
Wiring harness create
Wire routing create
Clip mounting and stud mounting featuresTail lamp design
Create a complete tail lamp using a hot plate welding section
Lens rib height - minimum 8-10 mm
Interference - 1.5 mm
The thickness of lens - 2.5 mm
Housing thickness - 2 mm
Reflector thickness - 2 mm
Boss - m4x10 screw
Positive mounting for the lamp - m5 screw
Wiring harness create
Wire routing create
Clip mounting and stud mounting features
Course Seven:
Wiring Harness
using CATIA V5
1.Basics of Vehicle Electrical
Distribution System & Wiring Harness
Introduction to Vehicle Electrical Distribution System (EDS)
Introduction to wiring harness assembly
Wiring harness design process for New Product Development (NPD)
Introduction to CATIA V5 electrical workbench

2.Introduction to CATIA V5 Electrical Workbench &

Electrical Part Design
Customized settings for electrical environment
Wiring harness routing process for CATIA V5
CATIA V5 – electrical part design
3.Electrical Part Design
Clip/clamps/support part definition
Backshell definition
Protective covering definition

4.Harness Assembly & Installation – Part 1

Preparation of harness assembly
Creating the wire harness geometrical bundle
Inserting harness components into geometrical bundle
Positioning your inserted electrical parts
Connecting & Disconnecting electrical components
Defining the wiring harness routing

5.Harness Assembly & Installation – Part 2

Wiring harness routing on external references
Modifying the wire harness bundle segments
Wire harness protective coverings
Use of electrical splices
Bundle continuity check/analysis
 Geometrical bundle warnings
3D annotation

6.Harness Assembly & Installation – Part 3

Modifying the wire harness bundle segments
Modifying the branch point location
Deleting bundle segment
Bundle continuity check/analysis
Geometrical bundle warnings
3D annotations
Important commands, tips, & techniques

7.Wiring Harness Flattening

Wiring harness flattening workbench
Flattening workbench settings
Flattening the 3D harness assembly
Modify flatten assembly
Saving the flatten Files
Drawing, creation & contents
8.COMPONENT
SPECIFICATIONS
& SELECTION GUIDE
Wiring harness component specifications & selection
parameters
Available suppliers in market (India)

9.Wiring Harness Routing & Packaging

Basics – Session 1
Definitions
Routing & packaging process
Design criteria (generic) for wiring harness
Packaging rules & best practices
Guidelines for battery cables routing
10.Wiring Harness Routing &
Packaging Basics – Session 2
Clearance management
Water ingress protection
Thermal protection management
Chaffing protection
Vibration protection
Routing on/near dynamic parts ( engine, wheel)
Harness bending rules (harness & battery cables)
Interconnection connector parking

Projects Overview
Project 1 - The Engine
Wiring Harness on Engine
Route the wiring harness on the given engine and prepare to flatten view drawing in CATIA V5. Application of all
packaging rules, Industry best practices studied in this course shall be demonstrated in design. Apply protection
coverings as required.

Project 2 - Car Body

Wiring Harness on Car Body
Route the wiring harness on the given car body and prepare to flatten view drawing in CATIA V5. Application of all
packaging rules, Industry best practices studied in this course shall be demonstrated in design. Apply Protection
coverings as required.
Sketching
Specialization
Course One:
Automotive
Sketching
1.Introduction
This is an introductory week. We will first look into what exactly is Design and then try opening it up with its family tree &
branches as Automobile Design is a categorized part of Industrial Design. So, the entire process of it will be explained. We will also
be discussing what will be the job of a designer in this role? We will also cover the history perspective along with evolution in
design. And towards the end of the week, we will be looking into trends in Elements of Design. Then we will move on to Shape &
Form design & its differences.
What is Design?
Overview- Industrial Design & Introduction – Industrial Designer
Overview- Automotive Design & Introduction- Automobile Designer
Design Process-Introduction
The Basic Design Process
Important roles in the Design Process
History of Automobiles
Historical perspective on Car Design
Evolution of Design
Trends in Automobile Design
Elements of Design
Shapes & Form in Design
Introduction to Shapes & Forms
What are Forms?
Difference Between shape and form

2.Shape transformation and translation

This week, we will be having a recap of the content we learned last week. This week, we will give more emphasis to form design
topics, we will look into how to form design is used to build forms, Shape Translation & Transformation. The two important topics
of this week are “Elements of Design” & “Principles of Design” teaching. We are giving more importance to these topics as they help
us understand the design philosophy.
 Transformation
Form Design-Continuation
Deconstruction
Forms in Automotive
Speed forms
Elements of Design
Principles of Design

3.Introduction to car design

This week, we will be introducing you to how exactly the exterior body of a car is done. Once this is done, we will move into the
aspects that cover automotive design. We will be looking into the entire exterior terminology. The week’s videos will also help you
understand the industry language for those parts. We will be covering the engineering aspects later. You will finally be starting
your practice to generate freehand sketching
Automotive Design- Body Styles, Layout, Proportions and Themes
Automotive Exterior Terminology7
Engineering Aspects
Introduction to freehand sketching of simple geometries

4.Introduction to isometric and perspective

This week, we move on to a rather peculiar phenomenon or concept of drawing- perspective. But first, we will have a look at how
things work in isometric and then we will start with different types of perspectives. Then once completed we will start sketching in
perspective. This will help us understand what are the different parameters one needs to keep in mind while drawing each and
every sketch. Moving to a car sketching block, while making one in perspectives it is vital that we understand how it affects the
angle.
Isometric perspective - Working with Isometric grid
Types of perspectives
1 point
2 point
3 point
Multipoint
Learning sketching in perspective: 1 point, 2-point & 3-point perspective.
Working with perspective Grid
Sketching car block in 1, 2 & 3-point perspectives freehand
Exterior and Interior Design
Understanding Exterior proportions
Sketching car side view proportion boxes- Sedan, SUV, Sports car, compact car & truck
5.Sketching of Car’s
Front and Rear Views
This week, you will be taken up a bit with ¾th perspective
sketching, later on, you will learn about aesthetics. It will
also give you an idea about the important vehicle
ergonomics & packaging. After that will cover the technical
side, and learn how to make a technical drawing. Coming
to the Artistic side we will understand the basics to make
different shapes & forms to understand the surface.
Sketching car ¾ front view, ¾ rearview Box as per proportions
Automotive Aesthetics
Vehicle Ergonomics
Vehicle Packaging & Benchmarking
Technical Drawing
Understanding Surface Shapes & Form basics

6.Shading & Basic Reflections

This week, we will start with the basics of shading & reflections. Then after that will try a technique to render with different
mediums. Will learn how a project basis is formed by desk & market research. Then coming to the user research, you will be
learning how to make a design & mood board depending on your requirement and personality. Once completed we will
take inspiration and create forms. We will then try to doodle and draw different shapes. And then finally we will see how a
car is sketched by a step by step guide.
Basic Rendering Technique using a different medium
Desk Research & Market Research
User Research- Target User
Design & Mood Board- Inspiration Board
Inspirational Driven form
Doodle & Draw
How to draw Car side view- A step by step guide

7.Introduction to sketching as a communicating tool

This week, you will learn how to use sketching as a tool to communicate. After that, we will go on to generate new forms and
will look at techniques of how to do it. We will also learn about building concept form and the classification of sketches. We
will then move on to a step by step guide to making cars in 3/4th perspective views while incorporating concept forms.
Form Generation Methods & Techniques
Sketches Classification & Basic – Ideation Sketches, Exploratory
Sketches
Creating Concept forms
How to draw Car ¾ views- A step by step guide
8.Understanding lights
and materials
This week, you will try to make a photorealistic render.
Then we will move on to understanding how lights &
materials work on surfaces. We’ll try rendering techniques
& implement all of the learning in the first Design Project.
Photorealistic Rendering
Reflection as on Car surfaces- Pencil Rendering & Marker Rendering
Design Project- 1 (1 week)
Design a Family Sedan. Keeping the brief in mind.

9.Introduction to Automotive Interior Design

This week, you will be introduced to the interiors of the car. Here, you will learn about crucial ergonomics and interior
occupant packaging. We will also look into the design for the 95th percentile rule. And at last, we will have a brief look at the
Panels & Consoles
Car Interior Ergonomics- Crucial Role
Design for 95th percentile
Vehicle Packaging & Benchmarking
Understanding the interiors-Occupant Packaging
Introduction to Interiors- Instrument panel & Consoles- Brief
10.Sketches
Classification& Basic –
ExplanatorySketches &
Persuasive sketches
This week firstly will learn another classification of sketches and will start with
the basics for the interior. Will have a look at the interior elements to
understand the principle behind each element. After that, I can focus on
sketching the interior as a whole. A study of trend Analysis & forecasting to
learn about the upcoming trends so it is easy to predict the future.
Understanding the Interior Elements
Back to Basics- Forms & Shapes
Interior Sketching- 1 Detailed Interior Components
Trend Analysis & Forecasting

11.Automotive Technologies
This week you will be learning about the relationship between automotive technologies and design. We will then be moving
to the interior as a whole, here, we will look into each element and discuss its role while experimenting with it with different
mediums. We will also be having a lesson on sketching with a sketchbook. So, you sketch directly onto your pc digitally.
Interior Sketching- 2 Detailed Interior Components
Different mediums for sketching- Explorations & its Effects
Digital Sketching- Sketchbook

12.Design Project
This week before introducing something new, you will be getting an assignment. You will be making an interior of a car with
all the elements. Later on, we will move to digital data & See how to render a car in a sketchbook.
Design a Certain type of vehicle interior with all the requirements of Interior needs.
Effectiveness of Digital Work & Refinements
How to Render cars in sketchbook

13.Nature & form, Biomimicry in transportation

design.
This week you will understand the influence of nature in form. You will learn the use of biomimicry in design and will
implement it in your design. As nature is the best creator. So, this is again a small project in which you will find and adapt to
what nature has to offer. And Make something unique.
Designing a vehicle while replicating a reptile or any mammal
Taking and breaking down its characteristics and using it in your own vehicle.
It can be a combination of 2 or a single
The characteristics of that reptile or mammal should be highlighted.
14.Products & brand
management
This week we will again start with a new topic. Here, you have to understand
Product & Brand management. The main reason we are focussing on it is
because it will help you to create a peculiar product for a potential customer.
Later on, we will move onto a new project in which we will redesign a certain
car, with its brand intact.
Redesigning an existing vehicle (pre-existed or current)
Understand the brand what they offer or the reason why they made that particular Vehicle.
Propose your Ideas while keeping the form and design intact from that original vehicle.
When you look at both of them the resemblance should be there.

15.Transportation Design- design of a minimised

roadster with a complete interior and exterior.
In previous weeks, you have covered several Projects in which a particular topic was only in play. This week we will be doing
another project which is bigger at play and has all that you have learned. Start with a design process. This particular week we
will decide the concept and ideation, later on, we will refine the design and finalize the exterior.
Exterior Preliminary Sketches
Initial sketches for concept generation and ideation for exterior or have an idea in mind what you will propose.
Exterior Refinements & Finalization
Status updates on whatever changes or refinements suggested on the exterior design & finalize exterior Design first

16.Interior design
This week is an extension of the previous week. In this, you will be focusing on the interior part of the car. As the exterior of
the car is finalized now with the same process, design the interiors. Start with preliminary concepts and then finalize the
interiors.

17.Transportation design project 2

This week again you will start with a new project. This will be again for 2 Weeks in which the entire process of Research,
Boards & Finalization will be followed. We are giving more emphasis on projects as this is a subject which can only be learnt
with hands-on practice and this way you learn and get used to things happening in the industry. For this, we are actually
going to design something for the year 2033. In which a lot will be depending on the research that you will do. A certain
brief will be provided to you so you actually go on and work from the basics. You will be working on a tight timeline so plan
accordingly.
 Mobility Design 2033- Decide your Concept 2033
Find a problem, build a solution, think of a concept, decide an action plan, propose proposals and presentations.
Design Research- Brand Identity, Target Customer, Concept
Sketch Presentation- Form Sketches, Proposal Sketches
Rendering- Selected Sketches, Final Rendering
Exterior Design
Exterior Preliminary Sketches Initial sketches for concept generation and ideation for exterior or have an idea in mind what
you will propose.
Exterior Refinements & Finalization Status updates on whatever changes or refinements suggested on the exterior design &
finalize exterior Design first

18.Interior design
Following last week, the exterior is completed and now we start with the interiors. Firstly, try to focus on the elements, after that
focus on the design part. Be free with your ideas! as there is no limit on thinking. We are creating for the future. But, think
realistically. At last, get everything rendered in a sketchbook and submit it as a presentation.
Following are the checkpoints to be covered for the same:
Interior Preliminary Sketches
Initial sketches for concept generation and ideation for interior
Interior Refinements & Finalization

19.Introduction to transportation design (final project 1)

Welcome to the final project. This week, we are going to start this project which will be completely your own. You will make a brief
of what you want to make, decide your users, and follow the entire process of design to take your idea to a final stage.
Make your Own Brief
Design Research- Desk & Market Research
User Research- Target Customer, Design / Mood & Inspiration Board
Research the Automotive technologies
Prepare a Trend Analysis & Forecasting Report
Build for a brand- Product & Brand management Report
20.Design Brief- sketching
after Ideation, Inspiration
and Exploration(Final
Project 2)
As the procedure for doing research and collection of data is clear to you, this week you will start with the conceptual phase by
taking inspiration. You will then provide the ideations for your design. You have a lot of time to think and explore your ideas. Try to
solve/create something better or different from your design.

21.Exterior design finalisation (Final Project 3)

This week, our main focus is to finalize the exterior design, the refinements have to be implemented early so that we can make
technical drawings of it. Later on, we wish to start with the preliminary sketches of interior design if the entire exterior design is
finalised.

22.Interior design sketching (Final Project 4)

This week we start on the interior design aspect of your design. First, try to think of your vehicle and then start experimenting with
the things that you need for your interior. Try to build a relation between interior & exterior and try to be more expressive by using
different perspective views. Focus on interior components, the looks and functions. Do an ideation sketch so everything becomes
clear.

23.Interior design finalisation

This week is totally focused on finalising the interior design. The main focus is to finalise the direction of our ideation and purpose.
Later on, work on refinements and finalize the interior with detailed Interior elements sketches.

24.Final Renders
In this last week, you will do the rendering & produce your design within a presentation. So the entire design process is clear to
someone who will look at the presentation. And in the end, we will be having a session where we will be discussing techniques to
better present your product. We will also discuss techniques that we need to focus on while designing.
Projects Overview
Project 1
Try to draw different shapes and assume the light, material and
shade areas
Trying photorealistic Rendering and submit one.
Try the Reflection techniques with pencil and markers
Complete the entire Design project with all the views with pencil
shading. Try to explore your options.
Basic Beginner rules for sketching & Practice

Project 2
Try to make sketches which explains a function & try to communicate idea by persuasive sketches
First understand the interior elements & following the process using basics, try out different shapes for interior.
Try to cover all the elements
Make a report on trend analysis & Forecasting, Considering

Project 3
Make a report on Automotive Technologies and there use in industry
Make all the components of interior like Steering, door panel etc.
While sketching tries to work with different mediums to explore the efficiency and quality
Practice sketching on the digital media but stick to pencil n paper for now. First get your hands on this.
Basic Beginner rules for sketching & Practice

Project 4
Complete the Design Project, again imagine the user and make an interior sketch.
Try to Sketch directly into sketchbook and then use the tools to render by applying the same principles we covered in pencil
& marker rendering.

Project 5
Submit a Report- Nature & Form- Research about what is going to be the problem and your solution from nature.
Mention the reptile or mammal you are taking as inspiration, its properties. Point out the reasons, theory behind why or
because of what reason It is like this. Ad how It is a best fit for your solution.
Derive the Ideation, take inspiration, and come up with the Form and its functional usability and Finish this project. Request
you not to copy.
Project 6
Submit the Report in which state a brand, year of
vehicle & what was the brand offering during that
time. Now, what has changed.
Start with the brand & Redesign in a sense that at first
looks they both look similar. Try to understand what
the company, their Design language, brand identity,
etc.
Finish the project in a manner that a differentiation can
be carried out of what was there, and what you made.

Project 7
Follow the Design Brief and completed the exterior for Minimised Roadster.
Submit the finalized Design sketches or render it is up to you. If you are Comfortable in Sketching & Shading, those finalized
sketches are also fine.
Design interior with same design language & follow the same process
Ideate Interior and Finalize a design which you thing well suits with your Design.
For final submission you can make a presentation and put in your sketches. Rendering the interior is up to you with any
medium. (Not necessary for this project)

Project 8
Prepare & Submit the report on the technologies which are currently in the market incorporated in the automobile industry
and what are the future trends
Depending on which what problems you think will be there and What is your solution.
Follow the entire Design process of User Research, Target user, Make Design Boards- Mood Board & Inspiration Board.
Exterior Design ideation, Explorations & Finalize your Exterior Design.
Complete the entire sketch finalization of interior & Render the views.
Submit a presentation of all the projects in which everything will be mentioned like all the boards, users & sketches for both
interior & exterior and then final renders.

Project 9
Submit the entire presentation containing your Design brief- Explained
Desk Research, Market Research, User Research (Provide separate links as well for Data research)
Mood Board & Inspiration Board with Keywords
Automotive Technologies, Trend Analysis & Forecasting Report
Start with ideation if data is completed.
Submission of the Preliminary Sketches and mention of the direction that you want to go ahead with. Prepare a
presentation so it is easy to check the entire Process, or you can make it an addition in the previous presentation
Submission of Finalized exterior Sketches in the direction that you chose earlier.
A technical drawing for the same with the entire packaging data.
Addition in the previous presentation.
Submission of Interior ideation & exploratory Sketches and mention of the direction that you want to go ahead with.
Addition in the previous presentation
Submission of Interior Finalized sketches.
Addition in the previous presentation
The necessary Final 3 views have to be submitted are Side view, front 3/4th quarter view & rear 3/4th quarter view. Rest you
can do additional if you like.
Submit the presentation containing all the process from start till the final
 Sketching
Specialization
Course Two:
Automotive
Class A surfacing
using ALIAS
1.Digital design Foundation 1 & Curves
Introduction, Why Use Curves
Introduction to Alias
What is Design? About CAID/CAD Design
User interface and Navigation Tools
Basic Object Selection and viewing
Importing Sketches as images or canvases
Working with layers
Introduction to curve tools. Basics, U’s & V’s, spans.
Create Symmetrical Curves
Transform Curves, Creating Curve Fillets, Curve Sections and offset curves

2.Digital design Foundation 2 & Building and

Controlling Simple Geometry
Controlling Geometry, Mirroring, Grouping, Duplicating Objects
Object Lister, CV Sculpting, Concept Sculpting

3.Digital design Foundation 3, Surface Editing

& Introduction to Different Continuities
Surface toolbar, edit and shade
Difference Between Surfaces and Solids
Surfaces from Boundaries, Bezier surfaces,
Nurbs & Slab Modeling
What are Parent surfaces? Primary surfaces, Secondary surfaces
Sharp Surface models
Primary fillets, blends, Secondary fillets, blends
Chord fillet & Radius Fillet
4.Surface Editing
Trimming, Creating Curves on Surfaces
Trimming Surfaces, Intersect Surfaces, Filleting Surfaces
Adding Variable Radius Fillets

5.Introduction to Different
Continuities
G0 - Positional
G1 - Tangent
G-2 - Curvature
G-3 - Curvature

6.Workflow 1: Concept Modeling

Introduction to Concept Modelling
Construction Options Introduction
Dimensions
Overlay canvasses for design and presentation.
Building with Curves & Surface Tools
Modelling approaches and Surface distribution
Working Accurately

7.Workflow 2: Concept Modelling

Overlay Canvass for design
Surface understanding by Three-quarter views.
Building with Curves & Surface Patching
Modelling approaches and Surface distribution

8.Workflow 3: Concept Modelling

Understanding of component design
Hypothetical surfaces to create patch layout
Work more on Creative side: Imagine the surfaces

9.Workflow 4: Concept Modelling

Understanding of component design
Hypothetical surfaces to create patch layout
Work more on Creative side: Imagine the surfaces
10.Workflow 5:
Concept Modelling
Understanding surfaces, patches, layout
Idea of how to divide surfaces
Building techniques, where to start
Make your way up to the top
Parent Patches- Foundation

11.Technical Surfacing (A- Class Knowledge)

Introduction to Technical Surfacing
Surface Evaluation - Reflection Lines
Surface Evaluation - Cross Sections & Comb Plots
Construction Tolerances between Surface Patches
Transform CV - Fine-Tuning Control Points
Working with Trimmed Edges - Fit Curve & Align Project

12.Class B Surfaces modelling

Fulfilling every parameter
A well thought patch construction
Patches with proper cv’s layout
Proper passing of positional, tangent and curvature surfaces
Proper evaluated surfaces
Making way up to Class-A Model

13.Reverse Engineering
Introduction to Reverse Engineering
Working with Mesh Data
Working with Sections
Creating a Surface onto a Mesh
Analyzing and Displaying Deviation
Reference Manager for Handling Large Data Sets
14.Presenting Your Design
Rendering in Alias
Hardware Rendering, Shades, Lighting, Environments
Creating Image Files

Projects Overview
Project 1 - Modelling Project
Model the Car of the given blueprint and prepare the CAS volume surface with the terminologies covered. Make sure the design
element isn’t suffered while building clean curves & Surfaces. The Process of creating, first- A patch curve network then surface
building shall be applied in Modelling. Create Curve network as Required. Once Volume has completed the process of filleting
should be applied to the entire model.

Project 2 - Presentation Design Project

Complete the detailed car model and the industry techniques we have studied in this course must be applied for rendering and
image creation. Apply different materials a visualize the best one. Complete other models as well and have it rendered while
preparing a presentation of all the 3D models.
Manufacturing
Specialization
One: Mold
Design using
SOLIDWORKS
1.Introduction
If you had the privilege of being in a FIAT Padmini, you would have noticed how the metallic interior and exterior stood out. It
was built like a tank because of which the car was heavy. If you notice the cars running on the streets today, the interior and
exterior have significantly more plastic components. Even if you take a look at many of the appliances that you use today, you
would notice the rise in the number of plastic components.

In India, the rate of growth of the plastics industry is almost 16% per annum as per a report by British Plastics Foundation. The
reports show that there is not going to be a drop in the rate anytime soon. With this, you can pretty much understand the
importance of the plastics industry and the time and effort that goes into making a plastic component.

We, at Skill-Lync, have come up with a course that will help you understand what you need to know to enter into this industry.
This course is tailored in such a way that anybody with a basic grasp of any modelling software will be able to finish this course.

The course contains 12 weeks of curated content taking you through the very basics of SOLIDWORKS where we help you master
all the commands required for you to start working on the tool. Following which you will be introduced to the basics of plastics
and injection moulding where you will get a better understanding of the processes involved. We then take you through the
steps involved in creating a basic mould for simple parts. Over the following weeks, you will be introduced to more complex
concepts in mold design.

Through the duration of this course, you will be required to work on challenges that pertain to each week of content so that you
get to work on the models that you see in the explanation videos as well as extra models that will challenge you to think ahead
and use the concepts learned in the videos
2.Basics of Injection
Molding/SOLIDWORKS
Surfacing
This section will cover the following basic concepts
Injection molding process and how it works
Plastic processing methods such as
Rotational molding
Extrusion
Vacuum forming
Blow molding
Gas-assisted injection molding
Mold cycle and the factors affecting it
Thermoplastics and thermosets
The current trends in the industry
The types of plastics being used
The properties of these plastics and,
How to select them
For the uninitiated, we’ve also included a session on the basics of SOLIDWORKS where we take you
through
Basics of sketching
Basics of using features in SOLIDWORKS

3.Basics of Mold Design / SOLIDWORKS Surfacing

After getting a basic understanding of injection molding from the previous session, in this session we will jump into the
technical side of designing the mold. The topics we will be covering are:
How the product development process takes place in the plastic industry
Various departments in plastic manufacturing industries and the workflow
Parts of mold - core, cavity, guide pillar, sprue, register ring, guide bush, ejector pin, return pin, spacer blocks, core
plate, cavity plate, ejector plates, etc.
2 plate & 3 plate molds
Drafts
Parting lines
In the SOLIDWORKS session, we will continue where we left in the previous session and learn about the various surface tools
used for designing.
4.DFM and Defects
In the third week, we will be covering theory related to various
concepts and terms used in mold design. The topics we shall cover
are:
Concept of machine tonnage and how to calculate it
DFM study where we will look at various concepts such as gate point, wall thickness, cores,
tolerance, venting, ejector pads, inserts, ejector inserts, guide pillar, support block, relief, free play
inserts, multi-gate position, and flow leader.
Various defects that may occur during the mold design process such as short shot, flash, weld lines,
sink marks, blisters, jetting, burn marks, warpage, gloss differences, hesitation, overpacking, and
unbalanced flow.

5.Parting Surface / Mold Design Tutorial 1

In the fourth week, we will be studying the theory behind parting surfaces. The topics that will be covered are as follows:
What is a parting surface?
Types of parting surfaces such as flat, stepped, angled and profiled parting surfaces
Example cases where we will try to understand the selection of parting surfaces
Matching drafts
Shrinkage
Inserts

In the SOLIDWORKS session, we will start with our first mold design tutorial. We will be covering a simple plastic component and
we will learn the following:
Doing draft analysis for the model
Creating parting lines
Creating shut-off surfaces
Creating parting surfaces
Create basic mold blocks
6.Sliders and Ejection
System/ Mold Design
Tutorial 2
In the fifth theory session, we will be looking at the topic of sliders and ejection systems. The topics that will be covered are:
Need for sliders and their working.
2 general types of sliders - sliding split type molds and the angular lift pin type molds.
Methods of actuating the sliders such as finger cam, dog leg, cam track, spring and the hydraulic actuation
Concept of slider locking
Various types of ejector systems such as pin, sleeve, stripper and blade ejector systems.
In the SOLIDWORKS session, we will be creating a mold for the outer cover of a disposable camera. The steps we will follow are
mentioned below:
Creating parting lines, shut-off surface, parting surface, and mold blocks for the model.
Creating ejector pins for the mold.
Creating inserts for the mold.

7.Gates and Runners / Mold Design Tutorial 3 - Part 1

In the sixth week theory session we will be learning about runners and gates. The various topics covered are as follows:
Types of gates such as sprue, edge, tab, overlap, fan, disk, ring, spoke, film, pin, submarine and cashew gates.
Runner diameter calculation
Types of runners
Runner configurations
Why engravings are used in cavity
Then in the SOLIDWORKS session, we will be creating a mold for a door bezel model. The topics that will be covered are as follows:
Creating the parting lines, shut-off surfaces and parting surfaces of 3D profile for the model.
How to work in assemblies and how to arrange files in a specific format.
How to align the sprue of the mold with the origin of the assembly.
How to select proper dimensions for the mold blocks.
Creating mold blocks for door bezel.
 8.Mold Design Tutorial 3
- Part 2
In the seventh week, we will continue working on the door bezel
model from the previous session and learn the following topics:
Locating undercuts in the model and understanding how the
use of sliders will help in solving the undercut issue.
Creating slider split
How to assign proper dimensions to the slider
Editing the core cavity blocks according to the shape of the
slider.
Creating bolts, washers and locking mechanism for the
sliders.

9.Mold Design Tutorial 4 - Part 1

In the eighth week, we will start creating a mold for a CPU fan case model and we will learn the following topics:
Complex parting line selection that can reduce the number of sliders required for the model.
How to provide correct matching drafts for the model.
Then we will create the core-cavity surfaces for the model. After that, we will align the sprue location, select dimensions
and create the mold blocks for the CPU fan case in assembly. We will also see how to add reliefs for the core-cavity blocks.

10.Mold Design Tutorial 4 - Part 2

In the ninth week, we will continue working on the CPU fan case model and we will learn the following topics:
Locating undercuts in the model
Creating a slider split for the undercuts.
Assigning proper dimensions for the sliders.
Providing reliefs for the sliders.
Creating inserts for the model.

11.Mold Design tutorial 5 - Part 1

In the tenth week, we will start creating a mold for a plastic knob model and we will learn the following topics:
Creating the parting line, shut-off surface and the parting surfaces for the plastic knob model model.
Automatic and manual shut-off surface creation.
Core-cavity surfaces for the plastic knob model.
Sprue alignment
Selecting dimensions and creating the mold blocks for the plastic knob in assembly.
We will also be covering some theory behind the cooling channels for a mold.
12.Mold Design Tutorial 5 - Part 2
In the eleventh week, we will continue working on the plastic knob model and we will learn the following topics:
Creating multiple inserts for the model
Creating holes for fixing the inserts.
Locating undercuts and creating a slider split for it
Complex slider creation
Assigning proper dimensions for the slider.

13.Mold Design Tutorial 5 - Part 3

In the twelfth week, we will continue working on the plastic knob model and we will learn the following topics:
Creating an ejector system which will include the angled ejector pins, reliefs, ejector plates and ejector back plates.
How to make the channels for plastic injection which will include the sprue, runner and gate for the mold.
Understanding the use for providing air vents in a mold and then creating channels for the passage of air from the mold.
How to select the dimensions and positions of the cooling channels in the mold and how to create them.

Project Overview
Project 1
Creation of Mold for the Outer Casing of a Table Fan
For your first project on mold design, you will be working on creating a proper mold for a table fan stand. Though the table fan
stand may appear to be a fairly common and simple product to manufacture, due to the presence of undercuts (explained in the
course) in the model, it is actually not possible to manufacture the product using just two standard core-cavity mold blocks. In
order to deal with external undercuts along with the creation of proper core-cavity mold blocks, the creation of proper
additional sliders is also necessary. The process of the creation of sliders will be covered in the course for other models. The
students will be expected to understand the concept of sliders applied to other models covered in the course, and then apply
those concepts learned to the table fan stand model. Thus, working on this project would prove to be both challenging as well
as provide insight and experience on how to use sliders while creating a mold for a component.
Manufacturing
Specialization
Two:
Automotive
BIW Fixture
Design using
CATIA V5
1.Introduction to BIW-Fixture
Definition of BIW, jigs & fixture
BIW-nomenclature
Types of fixtures & their applications
BIW stations & their uses
Basic terminologies

2.BIW-Fixture Basics
Project activities
Different welding processes
3-2-1 principle
Body planes

3.Pre-Design Processes
Design Methodology
Structuring a design tree
Different types of fixture units

4.Units Design-1
Different types of Pin Unit Design
Different types of Clamp Unit Design
Different types of Rest Unit Design

5.Units Design-2
Dump Unit Design
Slide Unit Design
Base Unit Design
6.Finishing the Design
3D-finish
Rough locators
Pneumatic routing
Valve banks & selection
Gun study
Sensors & selection

7.2D-Detailing Basics
Drawing templates
Angles of projection
Basic GD&T used in fixturing
Scaling & views
Various detailing patterns

8.2D-Detailing 1
Key Sheet detailing
Unit detailing
Child parts detailing

9.2D-Detailing 2
Child parts detailing continued
Material selections
BOM preparation

10.Documentations
Design terminologies
Sequence sheets
Clamp validations sheets
Ergo-sheets
Poka-yoke
Fixture process sheet
Cycle time study
Projects Overview
Project 1 - Robot Welding
Designing a Robot
Welding Fixture
Developing the complete fixture assembly with all
the necessary units (like pin unit, clamp unit, base
unit, rough locators, etc) for the given BiW
assembly
Preparing 2D assembly drawing and child part
drawing for all the relevant parts of the fixture
assembly
Preparation of BOM and BOP as a part of the
output documentation

Project 2 - Manual Welding

Designing a Manual Welding Fixture
Developing the complete fixture assembly with all the necessary units (like pin unit, clamp unit, base unit, rough locators, etc)
for the given BiW assembly
Preparing 2D assembly drawing and child part drawing for all the relevant parts of the fixture assembly
Preparation of BOM and BOP as a part of the output documentation